Test B: Fuel Gauge Reads Incorrectly
- Turn ignition switch to RUN position. Using New Generation Star (NGS) tester, select instrument cluster FUEL LEVEL CONTROL active command. Trigger, observe and scroll FUEL LEVEL at 0 %, 50% and 100%. Fuel gauge should indicate below E with 0 %, half with 50% and full stop with 100%. If fuel gauge operates as specified, go to next step. If fuel gauge does not operate as specified, go to step 8.
- Test fuel gauge. See FUEL GAUGE TEST under COMPONENT TESTS. If fuel gauge functions correctly, go to next step. If fuel gauge does not function correctly, go to step 7.
- Turn ignition switch to LOCK position. Visually inspect fuel tank for any damage or deformation. If fuel tank is okay, go to next step. If fuel tank is not okay, replace fuel tank. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. Retest system operation.
- Visually inspect fuel tank assembly, harness, float and float rod for damage or obstruction. Repair as necessary. Retest system operation. If fuel tank assembly and harness are okay, replace fuel gauge sending unit. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. Retest system operation.
- Disconnect instrument cluster harness connector C220a. Turn ignition switch to ON position. Measure voltage between ground and instrument cluster harness connector C220a terminal No. 3 (Yellow/White wire). See Fig 1. If any voltage is present, repair short to voltage in Yellow/White wire and test system operation. If no voltage is present, go to next step.
- Turn ignition switch to LOCK position. Disconnect fuel tank assembly 4-pin harness connector C433 or 8-pin harness connector C4033. Remove instrument cluster to gain access to instrument cluster harness connectors. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Disconnect instrument cluster harness connector 220a. Measure resistance of Yellow/White wire between instrument cluster harness connector C220a terminal No. 3 and fuel tank assembly 4-pin harness connector C433 terminal No. 1, or 8-pin harness connector C4033 terminal No. 5. See Fig 1, and Fig 2 or Fig 3 . Measure resistance between ground and instrument cluster harness connector C220a terminal No. 3 (Yellow/White wire). If resistance is 5 ohms or less between instrument cluster harness connector and fuel tank assembly harness connector and more than 10 k/ohms between ground and instrument cluster harness connector, go to next step. If resistance is more than 5 ohms between instrument cluster harness connector and fuel tank assembly harness connector and less than 10 k/ohms between ground and instrument cluster harness connector, repair open or short to ground in Yellow/White wire between instrument cluster and fuel tank assembly. See WIRING DIAGRAMS . Retest system operation.
- Measure resistance in Black/Orange wire between instrument cluster harness connector C220a terminal No. 4 and fuel tank assembly 4-pin harness connector C433 terminal No. 3 or 8-pin harness connector C4033 terminal No. 8. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in Black/Orange wire. See WIRING DIAGRAMS . Retest system operation.
- Turn ignition switch to LOCK position. Check for corrosion, pushed out pins and harness connectors that are not connected correctly. Repair any damage found and reconnect any loose harness connectors. Retest system operation. If problem does not exist, system is operating correctly at this time. Clear any DTCs. If problem exists, replace instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Retest system operation.
NOTE:
Non-California models are equipped with a 4-pin fuel tank assembly harness connector (C433). See Fig 2. California models are equipped with an 8-pin fuel tank assembly harness connector (C4033). See Fig 3.